SIMULATION DRIVEN OCCUPANT OPTIMIZATION, ROBUSTNESS ... · •Instrumental Panel Impact Tool...
Transcript of SIMULATION DRIVEN OCCUPANT OPTIMIZATION, ROBUSTNESS ... · •Instrumental Panel Impact Tool...
SIMULATION DRIVEN OCCUPANT OPTIMIZATION,
ROBUSTNESS & POSITIONING
Ravi Kodwani : Technical Director, Altair Engineering Inc
About Altair
A Simulation-Centric Portfolio for Design, Data Analytics, Cloud and AI.
$396MFY18
Revenue
2,500+Engineers,
scientists, and
creative thinkers
60,000+Users
1985Founded and
headquartered in
Troy, MI US
8,000+Customers
Globally
81Offices in
25 Countries
100+Software
products
Altair Partner
Alliance (APA)
High Performance
Cloud ComputingInternet of Things
Data IntelligencePhysics SimulationDesign, Modeling
& Visualization
Broad Portfolio of Comprehensive Solutions
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
HyperMesh
HyperStudy RADIOSS
HYPERWORKS : INTEGRATED CAE PLATFORM FOR SAFETY
Component
Meshing
Model
Building
Simulation
Results
Visualization
Reliability /
DOE/
Optimization
Altair / FTSS
Safety Tools
HyperView /
HyperGraph
Meshing
Connections
Morphing
HyperMeshDummy-Seat Positioning
Airbag, Seat belt Set-up
Airbag Folding pre-simulation tools
Robust, Scalable, Repeatable results
UP and FVM Airbags
Cut Methodology Airbag shape, Inflator
characteristics, Sensors
timing DOE and Optimization
for limiting occupant injuries
Easy templates generation for quick reports
Autorun in batch mode after simulation
Comprehensive set of Humanetics
and Altair Dummies
Barries and impactors
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SIMULATION DRIVEN OCCUPANT OPTIMIZATION,ROBUSTNESS & POSITIONING
AGENDA
Occupant positioning in HyperMesh
Seat Mechanism
Dummy Positioner
Seat Deformer
Belt Routing
Interlinked Environment
Occupant Safety post-processing
Robustness and Optimization using DOE and Optimization
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
EXEC SUMMARY
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
CRASH SOLVERS INTERFACES
HyperMesh 2019
CRASH Interfaces
Generic Keywords Support
Improvement
&
Support of New Solver
Versions
Total of 20 New Entities
Improved Parametrization
Capabilities
(LS-Dyna & PAM-CRASH)
Mass Calculation
&
Mass Summary Tool
Penetration Check(RADIOSS & LS-Dyna)
&
Model Checker
Solver Keywords based ID
Manager
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
CRASH & SAFETY – PEDESTRIAN IMPACT ANALYSIS
• HyperMesh offers following tools related to impact analysis:
• Pedestrian Impact Tool (Euro-NCAP, GTR, UN-R127)
• Instrumental Panel Impact Tool (FMVSS201 & ECE-R21)
FMVSS201 / ECE-R21Pedestrian Impact
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
CRASH & SAFETY – OCCUPANT SAFETY
• HyperMesh 2019 offers a complete
solution for occupant safety application
for RADIOSS & LS-Dyna solvers
• New Tool added to the occupant safety
tools portfolio
• Improvements in existing tools:
• Mechanism creation Lead Time reduction with
new automated mechanism builder process
Dummy positioner
Seat Mechanism
Seat defomer by pre-
simulation
Dummy deformer by
pre-simulation
Seatbelt
Seat & Dummy
coupling
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SIMULATION DRIVEN OCCUPANT OPTIMIZATION,ROBUSTNESS & POSITIONING
AGENDA
Occupant positioning in HyperMesh
Seat Mechanism
Dummy Positioner
Seat Deformer
Belt Routing
Interlinked Environment
Occupant Safety post-processing
Robustness and Optimization using DOE and Optimization
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
CRASH & SAFETY – SEAT MECHANISM TOOL
• Tool available for RADIOSS and LS-Dyna Interfaces
• Interactive and automatic modification of the seat position
• Save multiple positions of the seat for the different load cases
• Mechanism information (bodies, joints, positions) are saved in the solver deck after the
END keyword, using Primer MECHANISM syntax
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
CRASH & SAFETY – MECHANISM TOOL
• Automated mechanism creation process
• Mechanism creation time reduction from ~45min to ~5min
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
DUMMY POSITIONER
Dummy tree structure:
Reads Primer & LS-Pre dummy
tree
Export dummy tree in Primer
format
Dummy position can be saved:
As a position
As a dummy angle file
Move:
One joint at a time
Multiple joint with possibility to
constraint certain degree of
freedom
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
DUMMY POSITIONER
• Tool available for RADIOSS and LS-Dyna Interfaces
• Interactive and automatic modification of dummy limbs
• Save multiple positions of the dummy for the different load cases
• Dummy information (bodies, joints, positions) are saved in the solver deck after the END
keyword
Saved positions for different crash regulations
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
DUMMY POSITIONER
• Multiple targets point positioning allows to position the ATD precisely and easily
based on measurement made in tests
• Input is X,Y,Z measurement from tests
• Location of measurement corresponds to target modeled on ATD
• With simple script & a few rules the process can be automated and run in batch
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
CRASH & SAFETY – DUMMY PRE-SIMULATION
• Important tool for occupant safety simulation process, allowing to simulate the
deformation of the whole dummy using the cable method
• Automatic detection of the cable attachment nodes when those are not specified in the
dummy metadata
• Automated export of the pre-simulation solver deck (LS-Dyna or RADIOSS)
Initial position from dummy positioner
Simulated dummy position
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
DUMMY POSITIONER : PRE-SIMULATION
• Puppet method for pre-simulation and removing intersection after geometric
positioning.
• Simple process where the tool automatically computes the difference between the current
position and the reference position
• Export of pre-simulation input file to submit to solver
• Read result file (h3d or dynain) and optionally take into account pre-stress
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
CRASH & SAFETY – SEAT MECHANISM + DUMMY
• Ability to link a dummy to a seat mechanism
• Constraints can be use to fix the bodies of the dummy that should remain in position
(hands/feet)
• Dummy is automatically moved based on the motion of the seat
Initial seat+dummy position Modification of seat position New seat+dummy position
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SEAT DEFORMER
• Provides a quick and efficient way to remove intersection between the ATD and
the seat
• Optionally import initial stress (solid, shell, beam).
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SEATBELT
• Allow the full modeling of a seatbelt system
• All LS-Dyna seatbelt modeling supported (mixed 1D-2D, mixed 2Dseatbelt/shell,
• Automatic creation of slipring, retractor, pre-tensioner and attachments to the vehicle structure
• Automatic creation of contact
• Modeling of full shell meshed seatbelt
• Automatic seatbelt update upon dummy and seat motion
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
BELT ROUTING
• Interactive modification of belt path and belt ends
orientation
• New belt object in HyperMesh with all parameters defining
the belt (mesh size, mesh type, belt size,…) allowing
direct and quick modification of belt model.
HyperMesh Belt objectThorax belt creation Pelvis belt creation
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SAFETY TOOLS
• Complete restraint system generation
• Works in conjunction with the seat mechanism and dummy positioning tool to easily reroute the belt
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SUMMARY
• Seat Mechanism
• Reads and export mechanism in Primer format
• Following joint type are available
• Spherical
• Revolute
• Cylindrical
• Slider
• Double Slider
• Mechanism can be checked for error
• Nodes in multiple bodies
• Redundant joint
• Empty bodies
• Multiple position can be saved
• Dummy can be coupled to the seat
• Automatic extraction of mechanism
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SAFETY TOOLS
• Upcoming: Combining dummy pre-simulation & seat deformer
• Combining these steps will allow to improve efficiency as well as accuracy. Seat foam deformation will be
more realistic.
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SAFETY TOOLS
• Upcoming: Combining dummy pre-simulation & seat deformer
• Combining these steps will allow to improve efficiency as well as accuracy. Seat foam deformation will be
more realistic.
Deformable dummy Rigid dummy
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SIMULATION DRIVEN OCCUPANT OPTIMIZATION,ROBUSTNESS & POSITIONING
AGENDA
Occupant positioning in HyperMesh
Seat Mechanism
Dummy Positioner
Seat Deformer
Belt Routing
Interlinked Environment
Occupant Safety post-processing
Robustness and Optimization using DOE and Optimization
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
HyperGraph Report Template
© 2016 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Occupant Reports with HyperGraph
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
HYPERVIEW RESULTS TEMPLATE
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
• Multi-Disciplinary Design Exploration and
Optimization software for engineers
✓ Automates processes for parametric study,
optimization and robustness assessment
✓ Uses state-of-the-art mathematical methods and
data-mining
✓ Guides the user to gain insights from the data
collected
Study
Engine:DOE
Fit
Optimization
Stochastics
Model
ResultsResultsResultsResultsResults
VariantVariantVariantVariantVariant
SimulationSimulationSimulationSimulationSimulation
Study Results
Optimal parameters
Sensitivities
Model Robustness
…
Creation
Job
Management
Extraction
ALTAIR HYPERSTUDY
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
WITH HYPERSTUDY YOU CAN
Design of Experiments Fit Optimization Stochastic
Investigate
relationships
Make
predictionsIdentify
best design
Assess
reliability
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
HYPERSTUDY KEY DIFFERENTIATORS
Technology
State-of-the-art
methods for reliable
and robust product
design
Usability
Step-by-step process
that guides the user
Features such as
archive that improves
usability
Data Mining
Box plots, correlation
matrices, linear
effects, parallel-
coordinate plots
among many others
HyperWorks Integration
Seamless integration with
HyperMorph and Solvers
Automatic process
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
HYPERSTUDY USER INTERFACE
Streamlined
Process
Rich
Visualization
Efficient algorithms
Increased
Usability
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
AIRBAG SHAPE OPTIMIZATION WORKFLOW
Stable Load case
Tcl
Model Optimization ReadyParameterization : Morphing
and shape creationParameterization : Example
Airbag Properties
*.rad and includesHM Model
Hyperstudy Setup
Hyperstudy
Shape, a, b, c, d
Import
variables
Nominal Runs
Nominal Run
Responses
Setup Optimization
Optimization Setup
HPC
Hyperstudy Setup on
Linux server
Run Optimization
Optimized Results
Linux
Server
(a,b)
(c,d)
XREF to EREF Conversion
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
• Sled Test
• Airbag: Passenger Airbag
• Dummy: Hybrid III – 50th Percentile
• Design Variables:
• Airbag Shape
• Airbag tether lengths
• Vent area
• Vent timings
• Optimization Objective:
• Minimize Head injuries (HIC)
• Constraints:
• Volume
• Other Injuries
Example Load case
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
BASE SIMULATION RESULTS
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
Sect. 2
USER STEPS INVOLVED IN OPTIMIZATION
Sect. 3
Sect. 4
Sect. 5
Sect. 1
• Run tcl to create EREF and reference part from XREF geometry
• Parameterize Airbag properties and shape
• Setup Responses
• Setup Hyperstudy using a Hypermesh or parameterized tpl model
• Setup Hyperstudy on HPC Server (One time setup)
Sect. 6 • Setup Optimization
Sect. 7 • Results and post processing
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
SETUP HYPERSTUDY RESPONSES
Setup Responses
In the end, you should have a list of Responses defined as shown
(Optional:
Shown just for
example
Alternative to CSV
file reading)
Sect. 5
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
SETUP OPTIMIZATION RUN
Setup Responses
Step 14: Hit ‘Back’ from the Responses tab, and you will be taken to Evaluate tab of Nominal Run .
In the activity list on the right, uncheck everything except for Extract Responses step.
`
`
`
Click Evaluate Tasks, once it completes for all Nominal runs, you can check all the responses in Evaluation Data tab
Sect. 6
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
SETUP OPTIMIZATION RUN
Setup Optimization Study
Step 19:In Objective definition, Select Type as Minimize
Inside Apply On box, select appropriate Response, HIC 36 in this case.
``
Step 20:Go to Constraints tab.
Click Add Constraint > Label the constraint appropriately > Hit OK
Sect. 6
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
Sect. 7
RESULTS AND POST PROCESSING
Setup Optimization Study
Step 3: Go to Evaluation Data tab.
All runs and their results will be listed inthis tab.
One can right click on a variable orresponse and sort it by ascending ordescending order as well.
`
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
Sect. 7
RESULTS AND POST PROCESSING
Setup Optimization StudyStep 4: Go to Post Processing step.
In the Scatter 2D tab, select Correlationtab from bottom left.
In this chart, the number tell the intensityof relation between the design variablesand responses corresponding to givenrow and column.
For example, -0.76 in first row 5th columncorresponds to HIC36 and vent area.Select the cell and it will show the scatterchart for HIC36 and Vent area valuesfrom runs during optimization.
Negative value suggests that one entitywill decrease in value while otherincreases.
Usually correlation values greater than0.7 indicate significant relationship.
`
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
HYPERSTUDY RESULTS SAMPLE
Input variables and Response tables (Optimization / DoE)
Correlation Charts
(DoE / Optimization)
Pareto Charts (DoE)
Vent
area
Vent
delay
Lower
tether
length
Upper
tether
length
Middle
tether
length
Airbag
Shape
Scale
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
Back to IndexProcess Workflow
Sect. 7
RESULTS AND POST PROCESSING
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
REAL LIFE PROJECT FOR HIGHLY NON-LINEAR PROBLEM…
August 27, 2019 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.©
SUMMARY
• HYPERWORKS PROVIDES THE INTEGRATED SIMULATION SOLUTION FOR OCCUPANT SAFETY.
• NEW FEATURES FOR OCCUPANT SET-UP ARE CONTINUOUSLY ENHANCED FOR INTUITIVE, EASIER AND FASTER PRE-PROCESSING NEEDS.
• EASY TO CREATE GRAPHS AND TABLE TEMPLATES IN SYNC WITH ANIMATIONPOSTPROCESSING PROVIDES READY TO USE REPORTS WITH POSSIBILITY OFCUSTOMIZATION TO MEET YOUR SPECIAL NEEDS.
• HYPERWORKS DOE AND OPTIMIZATION TOOLS ARE INTEGRATED WITH PRE-POST-SOLVE TOOLS MAKE THE SET-UP AS ENGINEERS JOB RATHER THAN EXPERTS.